It is hard to fathom how this design ever made it to market. This is even worse than a water-damaged floor. Kudos to Chad and crew. Innovative solution and stellar work-ethic!!

@AZExpert

2 жыл бұрын

They are pretty talented guys! Thanks for watching! :)

“Made in America” doesn’t carry the meaning it once did. But watching the intelligence, imagination, pride and professionalism that went into fixing this problem is plain good for the soul. Well done guys!

@AZExpert

2 жыл бұрын

Thanks for watching!

@kenhansell1553

Жыл бұрын

So true. My brand new higher priced camper was junk a year after I bought it. If the japanese made a camper I'd buy it. The camper industry is a huge black eye for american quality.

@operator8470

11 ай бұрын

Yeah cause when it’s made in America nowadays it’s probably made in America by an illegal

Simple fix... techs hate it cause it cuts repair time hours. I know because I came up with this as a rv service manager. It works GREAT!!! Cut linoleum up carefully, use linoleum as template on 12 gauge sheet metal . If you can't install in one piece cut into sections, lay on floor and tack weld pieces back together, grind tack welds down and re install flooring . 12 gauge is super strong and is thin enough that it causes no slide out interference. Living room and kitchen area done in 8 hours or less, materials cost about $300. Have one full time rv couple that got this repair done 3yrs ago, still no problems and they each weigh 300lbs plus.

@AZExpert

2 жыл бұрын

Thanks for the comment

@kenhansell1553

Жыл бұрын

Since I work in a sheet metal shop this was gonna be my fix once I get around to it. Glad to hear it works!

Wow an amazing job. Mechanics fix the engineering mistakes. Great great video. Thanks for educating the masses.

@AZExpert

2 жыл бұрын

Thanks for watching! :)

@billlimbert1053

2 жыл бұрын

Great job, probably not as much a engineering issue as it was a cost savings issue. The dollar’s & unskilled labor dictate the RV industry. But the fact remains people will always buy the crap!

@xsterawesome

10 ай бұрын

​@@billlimbert1053Exactly, as an engineer the first thing you learn is everything is a balancing act (compromise). And when you're balancing cost weight and durability you got to take your use case into consideration. If your customer is trying to tow with a limited weight rating you know there's already a cost concern (or else they'd have a big diesel pulling a fifth wheel) we all know the average RV gets used four weeks a year, you can imagine someone who is budget constrained intends on using it less than that. This floor for light traffic is a great insulator lightweight and relatively low cost. I'm sure the same engineer could have worked out a carbon fiber floor that weighed less, had more stiffness than plate seal, and was a better insulator but would probably add $80,000 at retail to the price, the other end of the spectrum they could have just put in 3/4-in Granite throughout and increase the weight by like 2,800 lb plus the axles would have to be upgraded and insulation would have to be added because Granite is a good conductor of heat, but it would last a lifetime and only cost 40 bucks a square foot. I'd say the engineer made an okay call (I wouldn't make this call personally over customer headache alone) Objectively speaking I think this is more of a salesperson problem than a customer or engineer problem. An engineer's job is to match the design to the use case, salespeople are supposed to match a customer to a use case.

I have tried to contact Coachmen twice requesting comment, so far no response which says everything about this manufacturer. Thanks for the videos and educating us, we love it.

@AZExpert

2 жыл бұрын

I'm sure they wont comment

Thank you guys. Your work is so important to the rv community .

@AZExpert

2 жыл бұрын

Our pleasure! Thanks for watching! :)

@carmencolon3520

2 жыл бұрын

@@AZExpert Always ready to discover amazing rvs.

Solid rebuild. I just finished rebuilding my winnebago basement box that rotted out. What a PIA.

@AZExpert

2 жыл бұрын

Thanks for watching!

We had Cassone's do a second AC and washer dryer install while we were visiting AZ last summer. Excellent work with a quick turnaround! Thanks again Chad!

@AZExpert

2 жыл бұрын

Great to hear! Thanks for watching!

words can be hard sometimes. Nice to see what they did to fix it. Thanks for the video and explanation. Stay safe and healthy James.

@AZExpert

2 жыл бұрын

LOL Very hard!

They did an amazing job fixing the floor problems.

@AZExpert

2 жыл бұрын

I think so too!

Thanks James for the update on this trailer . It is a shame that manufacturers can get away with such poor construction techniques in the name of saving weight. It looks like Ultra lite means under built. I think the first trip out will/ should be to a weigh scale to find out the new unloaded weight which will determine the new CCC. The crew did a great retro fit on this TT !!

@AZExpert

2 жыл бұрын

Thanks for watching! :)

Nothing like reinventing the wheel on a piss poor designed coach😁 Kudos to them guys for that repair👍

@AZExpert

2 жыл бұрын

Thanks for watching! :)

Funny how the highly-trained industry manufactorors miss the mark, (by a long shot) then the untrained and creative with actual intelligence..... fix their b.s. handily. Who says actual workmanship and tenacity is dead in America???? This is one of my favorite videos. Seriously, great job!

@AZExpert

2 жыл бұрын

Thanks! But we are highly trained actually :D

It's amazing to me to see these manufacturers build these this poorly. You guys did good job fixing that.

I work in the same industry and have seen this far to often but 9nly in sections, I've done repairs very similar but have yet to see it happen to the entire floor. Good work

@AZExpert

2 жыл бұрын

Thanks! and Thanks for watching! :)

We redid our floor as well. 3 layers of paneling was stripped off a nd 2X2s of oak were put in beside the aluminum square tubes. We used 5/8 plywood instead of 3 layers of junk in our ultra light. Used construction glue and screws instead of staples. Forestriver Vlight.

@AZExpert

2 жыл бұрын

I hope it worked out well for you

Very nice work. Making something that wasn't built correctly in the first nice R&D by you guy's.

@AZExpert

2 жыл бұрын

Thanks for watching!

Man they did a great job. Chad'll take on anything

@AZExpert

2 жыл бұрын

Chad is a man of many talents

Outstanding work guys

@AZExpert

2 жыл бұрын

Thanks for watching! :)

I would suspect that most all ultra light trailers use this floor system and most of them develop these issues. Thanks for the video James. I appreciate it.

@AZExpert

2 жыл бұрын

Thanks for watching! :)

Nice job fixing the Roach Coachmen!!!

@AZExpert

2 жыл бұрын

Thanks for watching!

Great work. Expert is an understatement.

@AZExpert

2 жыл бұрын

Thanks for watching!! :)

Bummer on the build quality on that Coachmen. Thank you for this video. Happy trails!

@AZExpert

2 жыл бұрын

Thanks for watching!

Thanks for sharing! This is the content I was looking for.

Thanks for another informative video. Guys did a great job but something needs to be done so these companies can't sell all this high priced garbage as a RV. It amazes me how they get away with this stuff.

@AZExpert

2 жыл бұрын

Great point!

Im loving your videos! lots of experience. Here's a material tip. I use to buy 3/8" ply and have 1/32" thick aluminum sheets professionally laminated to both sides. This makes a very stiff sheet. This job would not need the sq tubing. just replace foam with a 3/8' thinner foam and put the 4X8 sheets on top.

Wow James just amazing what you guys do And reply to everyone’s questions 😎

Chad is the repair god.

@AZExpert

2 жыл бұрын

He is, but don't tell him that. He will be IMPOSSIBLE to work with. :)

Great info and insight as always! Shame everything is made disposable these days.

@AZExpert

2 жыл бұрын

Tell me about it! Thanks for watching! :)

Looks great. Something you should not have had to do if it was built right.

@AZExpert

2 жыл бұрын

Correct! Thanks for watching! :)

All of them are like this! Our Rockwood roo is really soft so following this closly. The dealers want over $2000 to fix.

@romeothompson9389

11 ай бұрын

Roos usually have a decent amount of square tubing already in place just but up some 2x2s and add to the square tubing and make bridges going across the tubing use expanding foam to fill in all the gaps and cut it flush to the tubing and 2x2s and go right over with 3/8 plywood or thicker if you don’t have a slide out glue and screw the plywood and it’ll be solid as a rock and the weight that your adding won’t affect anything you’ll be adding like 80 pounds to the camper if that

Beautiful work by those guys!!!!! BUT.....I still question the return on all the money/material/labor on a 6 year old low dollar trailer. I don't know if the next owner would even care, but I sure would

@AZExpert

2 жыл бұрын

It's cheaper than buying a new trailler

@AZExpert

2 жыл бұрын

They are not as low dollar as you think

Very glad I don’t own one of those. Thanks James! Kevin

@AZExpert

2 жыл бұрын

Thanks for watching! :)

excellent job and great choice of flooring !

@AZExpert

2 жыл бұрын

Thanks for watching! :)

You guys did a great job!

❤❤ Not being a nit picker Thresholds are entry, room to room are transition plates. Very nice job. 👍👍

@AZExpert

2 жыл бұрын

Thanks for watching!

Chad and Crew ROCK!!!!!!!!

@AZExpert

2 жыл бұрын

Thanks for watching!

Thanks for these videos

2017 - 35 foot Forest River Wildwood Heritage Glen Lite Travel Trailer. I am about to perform this very same operation. The flooring looks like an ocean now. In a month, it wont.

I have same problem i like what he did by putting in he braces. But i have one big question rule of thumb is never lay plywood with the grain going along the braces it would be stronger with grain going across the new braces same way as laying flooring in homes? Thanks for this info now i need just to jump in and get it done.

It's a shame that manufacturers take so little pride in engineering some of their products. In fact, it's pretty obvious that it was not designed by an engineer at all, but by someone waving their hands about what might be passable enough to sell. The beam stiffness of the flooring goes by the cube of its thickness. So going from 1/4 to 3/8 stiffens it by a factor of (3/2) cubed = 27/8. Now a 270 pound person will deflect it as much as an 80 pound person used to. Had they also securely glued or screwed the top flooring layer to it, it would have been stiffened a lot more than even that in the lengthwise direction of the boards, but very little crosswise (depending upon how strong any tongue/groove connection was). There are some interesting engineering solutions (honeycomb, isogrid, etc) for light weight and high rigidity, though they tend to be fully implemented only in aerospace applications where weight matters a lot and money matters almost not at all. Some of the same principles can be easily/cheaply used to create simple arrangements of standard sections (box, I-beam, C/U/angle-iron) that would allow the use of fairly thin subflooring by making it only cross small spans between supports. Maybe a grid of light supports within a grid of heavier supports. Likewise, the subfloor itself could be engineered a little to improve stiffness to weight. Thicker plywood lightened with a waffle pattern is stiffer than the same weight of thinner plywood. Stamped/drawn patterns in sheet metal, or hollow spacers welded between 2 sheets of metal, might make more sense for more consistent quality than machining plywood.

@AZExpert

2 жыл бұрын

Thanks for watching! :)

@charlevoix418

2 жыл бұрын

Coachmen hired their only designer in september 1972 and fired him in march 1973: it is quite obvious when you look at the interior decor...

I would think this also made the frame a bit stronger structurally and make it easier to level (less twisting) - but that is just a guess. Great video and insight.

@AZExpert

2 жыл бұрын

Very much so! Thanks for watching!

They do excellent work. It looks great.

@AZExpert

2 жыл бұрын

Yes they do. I'm glad it wasn't me :)

That looks expensive. Nice job!

@AZExpert

2 жыл бұрын

Thanks for watching! :)

You guys do good work

@AZExpert

2 жыл бұрын

Thanks for watching!

Could you have added angle iron underneath for structure support?

I’m to high to focus just a great video what’s the size of the plywood ?

It looks great. Much better than original “construction”. I wonder how much weight this repair added to the dry weight. Hopefully the owner takes this into consideration for cargo capacity.

@AZExpert

2 жыл бұрын

I'm sure he will

Nice work man!

@AZExpert

2 жыл бұрын

Thanks for watching! :)

To think the company actually had a meeting at some point and said how bad can we make this trailer

@AZExpert

2 жыл бұрын

Seems likely lol

This was amazing!

@AZExpert

2 жыл бұрын

Thanks for watching! :)

Nice work!!

@AZExpert

2 жыл бұрын

Thanks! and Thanks for watching! :)

This sounds very much like the American automakers in the 70s. They engineered cars to exact specs, and they fell apart in a couple of years. I kind of assumed the cabinets were somewhat structural. It seems like every static thing would have to help hold an RV together and upright. Kind of a shame manufacturers lowered the bar to the point they had to dig a pit to get lower.

@AZExpert

Жыл бұрын

It is a shame

-d'ya think RV builders will ever feature Bariatric models ? there are bariatric beds-600-1000 lb cap...

I've seen several video's of ultra light TT frames breaking because the frames are only 1/8 " steel. Scary!

@AZExpert

2 жыл бұрын

Very! Thanks for watching! :)

Outstanding work! Shame on Coachmen for putting that crap on the market.

@AZExpert

2 жыл бұрын

Thanks for watching!

What was the price tag for this repair as have same problem with 2013 Evergreen EverLite 29 FK!!!

What kind of adhesive did they use to adhere the wood?

Part of I-95 is built on 4' thick foam blocks... They had a roll-over of a fuel truck which really worried them since gas will melt the foam under the concrete... They did it that way to raise the road level above the water table since the 2004 hurricanes... I wonder how long it will last in real life!

@AZExpert

2 жыл бұрын

I suppose it depends on the type of foam. Most foam lasts forever--look at our landfills

@allangibson2408

2 жыл бұрын

Urethane foam is fuel proof. That is used to level already installed concrete from underneath. The canned spray foam is urethane. Polystyrene not so much. The styrofoam blocks used under concrete are just moulding for the concrete. Once the concrete sets they are non-structural with the load being carried by the cast concrete beams between the foam blocks.

HI! We have watched your videos and love your work. We just found the outside liner of our RV side panel split about 10"... whats the best way to fix. Can you do a video repairing this situation?

I have a 2015 Coachman Freedom Express (Liberty Edition) 298 REDS with the same spongyness. It started a couple years after I bought it (new) and now its bad enough I hardly want to walk on it! Do you have any idea if the floor construction is the same as this ulta lite. I was rebuilding the floor "in my head" before digging into it, but this certianly wasn't what I was expecting to see after I opened it up. Great Video!

Hmm...I've got a 2020 Apex Nano which boasts an aluminum framed laminated floor. I'm guessing that is similar to what you did to this trailer?

@AZExpert

2 жыл бұрын

Could be!

They did an excellent job. Hopefully, Coachmen is taking notice. I’m curious to know the type of the new flooring and color.

@AZExpert

2 жыл бұрын

It's stated at the end of the video

NIce. About how much did it cost to do?

It's somewhat a good design because it's lightweight and insulated pretty well. Making the floor a thick sheet of PVC would probably be the best because then it won't rot. But we all know the RV manufacturers would never do that

Now all this trailer needs is a lifetime roof.

@AZExpert

2 жыл бұрын

LOL Thanks for watching!

That is so disappointing to see. I hope to heck the owners insurance is helping out. ?? Like you said though, the OSB will still separate from the foam over time with foot traffic, but at least they’ll know they won’t end up with a Flinstones mobile.

@AZExpert

2 жыл бұрын

Thanks for watching! :)

Would you put a 300 pound pony in a toy hauler ? Aluminum frame

Great video. The big question is how much did this total repair cost?

@AZExpert

2 жыл бұрын

Sorry it's a customer unit, I don't quote prices

@dansouthcomb5439

2 жыл бұрын

@@AZExpert I was just wondering what the ball park price would be. Wondering if it would be worth th eprice to fix.

Are they willing to take on another Apex?? Mine will need the same repair soon

@AZExpert

2 жыл бұрын

You can always call and ask

i just bought an 2021 Apex. UGGGG

@AZExpert

2 жыл бұрын

:(

I love your videos, great work! Question, wouldn't it have been easier to lay the new flooring before putting the cabinetry back in? I'm thinking way fewer cuts.

@AZExpert

2 жыл бұрын

I feel like I need to make a new video addressing this

That must have cost a fortune. That's so disappointing. Hopefully everyone buying a travel trailer will watch this and ask the seller how its built, and then walk away if it was built like this.

@AZExpert

2 жыл бұрын

It's always good to do your research

@Jimmy_Jim_Jim_1234

2 жыл бұрын

@@AZExpert I will. Lesson learned thank you.

Looks to me like this probably didn't add a significant amount of weight and should've been the move to begin with

@AZExpert

2 жыл бұрын

Worth every pound

Hope you're okay! You werent looking too well in parts of that video...especially the end! Take care of yourself!

@AZExpert

2 жыл бұрын

I'll live :) Thanks for watching!

So glad for this video. My husband and I bought an ultra lite last month and didn’t have the weak subfloor (somehow) but we had a ton of water damage in the floor. We actually started demo before we understood what type of subfloor we had. Needless to say we’re lucky nobody fell through. My husband decided to do the repair in the exact same way it’s been done in this video except using 2x4s and furring strip to secure to the aluminum frame instead of welding aluminum supports in. If you made it this far and can help us though please do! We had to cut off the old damaged elevator bolts that were securing nothing buuuuuuut my husband accidentally cut the wrong ones. The one he cut is half under the wall and we can’t access it. So would you recommend cutting into the wall to create access to replace it or jacking the wall up off the bolt? Please help.

@Wythegoodsense

2 жыл бұрын

What did you guys do to repair/replace your floor?

Can you please explain why the fiberglass roof on the newer DRV feels like you’re going to fall through. Is it poor workmanship or the way it’s manufactured. Thanks in advance.

Any idea the rough ballpark cost of a repair like this?

@AZExpert

2 жыл бұрын

Sorry I don't quote repair prices on here

Could you weld a steel or diamond plate sheeting over the kitchen area for support?

@AZExpert

2 жыл бұрын

possibly, but I don't think it would have helped much

Would it be safe to assume all “ultra lites” have a similar flooring system? The issue I’m running into is that most smaller trailers (say 22-24’) are all marketed as ultra lite. Who makes a small trailer in a more traditional flooring system?

You will never run out of work or have a enough hours in a day to fix all the junk being sold .

@AZExpert

2 жыл бұрын

Correct! I would like a vacation

So sad that this happened as how many people can afford to fix! Great repair! What 5th wheel brand is well made in your opinion? Vanleigh?

what is this kind of floor repair approximate cost?

How much did this cost?

With all the issues in build quality, what are your thoughts on fiberglass molded trailers like Scamp, Bigfoot, or Escape? On the same note, if you were to buy a travel trailer, what would you buy and why?

@AZExpert

2 жыл бұрын

I do have a few videos on them

@wilko6324

2 жыл бұрын

@@AZExpert I looked through all of your video titles and saw a lot of traditional built trailers or motorcoaches. I enjoy your content, but as I'm watching you do repairs and inspections, I hadn't come across the fiberglass. Can you link the videos?

I want 2 inches of foam, 3/4 of luan, 1/4 of teak and holly plywood

@AZExpert

2 жыл бұрын

What you're looking for is a boat

What’s the cost of this job

I own a 2020 Coachman 289 tbss apex and within a year an a half same problem. Soft floor from the kitchen to the bunk house. It's just cheap crap that's all.

@AZExpert

2 жыл бұрын

OOF Thanks for watching!! :)

I don't suppose that this was covered by the warranty?😅

@AZExpert

2 жыл бұрын

Not sure. Thanks for watching! :)

did the manufacture offer up to help with costs. im thinking not.

@AZExpert

2 жыл бұрын

No

There are other ways they could save on weight. Making the floor out of styrofoam with very few supports seems criminal. Especially considering what people paid for these things. How many people did it take to come up with this idea? How many people approved it? How many companies adopted the practice?

@AZExpert

Жыл бұрын

You would be amazed at the construction or lack there of

That’s horrible, do they put a weight limit on the floor for people to walk on? I’ve meet some people (truck drivers) that go over 350 lbs or more.

@AZExpert

2 жыл бұрын

I'm sure different manufacturers do--I would expect them to hold up to the weight of several humans

Why do people buy this stuff? This rebuild looks good the factory should build them that way

@AZExpert

2 жыл бұрын

I agree, less work for me to do. Thanks for watching! :)

Can you give an estimate on cost? I reposted your original video on sites that reviewed this brand and model and there were crickets as no one wants to admit there are problems and no insurance or warranty to cover great job

@AZExpert

2 жыл бұрын

Sorry I don't quote prices on here

@lutomson3496

2 жыл бұрын

@@AZExpert hence my ask for an off the top estimate! ball park

Well it is a ultra light and now everybody knows why.

How many hours was this?

@AZExpert

Жыл бұрын

Several days

How did they get the floor under the wall

@AZExpert

2 жыл бұрын

Watch carefully lol

Is the cost of the floor repair more than the value of the 5 year old trailer?

@AZExpert

2 жыл бұрын

No

I believe that all RV mfrs. need to build to specified structural manufacturing standards. Right now there are none. Try getting a wiring diagram for your model.

@AZExpert

2 жыл бұрын

Thanks for watching!

Wow..

@AZExpert

2 жыл бұрын

Thanks for watching!